IRJET- An Experimental Investigation on Effective Utilization of Used Foundry Sand as Replacement of

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AN EXPERIMENTAL INVESTIGATION ON EFFECTIVE UTILIZATION OF USED FOUNDRY SAND AS REPLACEMENT OF SAND IN MORTAR Sunil B S1 Assistant Professor, Department of Civil Engineering, Bheema Institute of Technology, Adoni, Andra Pradesh, India ---------------------------------------------------------------------***---------------------------------------------------------------------(sand) was procured from Sakaleshpur and the used Abstract - In the present work an attempt is made to know the strength properties of mortar like compressive

foundry sand was collected from Shimoga Piston

strength and tensile strength at different curing periods by

Rings pvt ltd. This research is carried out to know the

replacing the fine aggregate by the used foundry sand from

performance of mortar contain leftover foundry

0% to 100 % by weight for 1:3 mortar mixes keeping the

sands a substitute of fine aggregate (Sand).

water cement ratio as 0.5. Along with the strength, the density, water absorption, sorptivity, water retentivity tests

1.1 OBJECTIVE

were carried out. Finally the prism compressive strength

The main objectives of the Project are:-

and flexural bond strength for 1:3 mortar mixes were

1. To economize the cost of construction without

discussed. From the results obtained, there is no much

compromising with quality.

difference upto 30% replacement of fine aggregate by the used foundry sand for most of the various properties of

2. To examine the utilization of Used Foundry Sand

mortar. But there is sudden decrease in values from 40%

as very well aggregate and influence of UFS on top of

replacement of sand since the used foundry sand has more

the Compressive power of gun made by means of

voids in it which results in less density and strength. At the

different replacement levels.

last the results were compared with the control mix and

3. To check the suitability of Used Foundry Sand as

discussed.

an alternative building fabric.

4. To arrive at the optimum used foundry sand

Key Words: Compressive strength, Tensile strength,

content for the mortar mixes.

Sorptivity, Prism Compressive strength, Flexural bond Strength

2. TESTS AND RESULTS

1.INTRODUCTION The present work concerns the investigation of UFS

In the present study, the tests were conducted both on fresh and hardened state of mortar for with and without

utilization effect on mortar. In particular, the

used foundry sand. The specimens of 1:3 mortar mix were

properties of mortars are investigated. The aim is to

prepared for 3days, 7days and 28days keeping the w/c

establish the quantity of used foundry sand so as to

ratio of 0.5.

be able to be additional in combine without

Following are the different tests conducted

incorporating too much into the mortar mix while knowing the behavioural properties of mortar in

1.Flow table test

2.Water Retentivity test

terms of strength and workability. The fine aggregate

3.Compressive strength

4.Splitting tensile strength

5.Dry Density Test

6.Sorptivity Test

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100

90

80

70

Flow Value (DfDi)×100/Di 110.08 97.85 87.14 75.71 63.57 54.28

60

0 20 40 60 80 100

Final Dia (Df) 14.76 13.85 13.10 12.30 11.45 10.80

50

1 2 3 4 5 6

Initial Dia (Di) 7 7 7 7 7 7

40

% of Replacement

30

Sl no

Water Retentivity for 1:3 mortar mix

20

2.1 Flow Table Test

100 80 60 40 20 0

10

Test

0

8.Flexural Bond Strength % Water retained

7.Prism Test

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% Replacement Chart -1: Water Retentivity 2.3 Compressive Strength Test Compressive strength of the gun for the control mix and with the incorporation of used foundry sand for different

Table -1: Flow Values

curing periods is determined by preparing the mortar

2.2 Water Retentivity Test

cubes by using the moulds of size (70.5*70.5) mm at

The property of mortar to keep the water next to

different curing periods.

suction and vanishing is termed as water retentivity.

The load taken by the mortar cube is noted. Finally the compressive strength of the mortar is determined by

It is determined by the flow of mortar when tested

dividing the load taken from the area of mortar cube and

on masonry unit like brick.

expressed in N/mm2.

Table -3: Compressive Strength of Mortar at 28 days

Table -2: Water Retentivity

% Replace

0 10 20 30 40 50 60 70 80 90 100

Wt of wet mort ar in (g)

Wt of dry mort ar in (g)

Origin al water conte nt

Water conten t retain ed

400 400 400 400 400 400 400 400 400 400 400

396 392 386 379 378 374 371 370 365 364 363

80 80 80 80 80 80 80 80 80 80 80

76 72 66 59 58 54 51 50 45 44 43

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Water retain ed in %(afte r1 hour) 95.0 90.0 82.5 73.7 72.5 67.5 63.7 62.5 56.2 55.0 53.7

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Average % Replace

Load in kN 1

2

3

compressive Area

strength N/mm2

|

0%

130

125

130

4984.36

25.73

10%

125

120

120

4984.36

24.40

20%

115

120

120

4984.36

23.74

30%

120

100

110

4984.36

22.72

40%

100

100

95

4984.36

19.72

50%

95

95

90

4984.36

18.72

60%

85

90

85

4984.36

17.40

70%

70

70

80

4984.36

14.70

80%

60

55

65

4984.36

12.02

90%

55

50

50

4984.36

10.36

100%

45

45

40

4984.36

8.70

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www.irjet.net 2.5 Dry Density Test

Table -5: Dry Density Values at 28 days % REPLACE 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Chart -2: Compressive Strength 2.4 Split Tensile Test Similarly, the tensile Strength of the mortar is determined by preparing the mortar cylinders of size (100*200) mm for different curing periods. The cylinders after the curing periods are then tested in compression testing machine to work out the tensile strength of mortar.

Average mass gram 812.00 804.00 793.33 777.00 769.00 760.33 752.33 750.66 738.33 733.33 727.66

Volume cc 351.89 351.89 351.89 351.89 351.89 351.89 351.89 351.89 351.89 351.89 351.89

Density= Average mass/ volume g/cc 2.31 2.28 2.25 2.21 2.18 2.14 2.13 2.12 2.09 2.08 2.06

Dry Density After 28 Days

% Replace

Load in kN

Dry Density g/cc

Table -4: Tensile Strength at 28 days Average Tensile strength N/mm2

2.4 2.2 2 1.8

2

3

0%

40

45

40

1.326

10%

35

35

40

1.166

20%

35

35

35

1.114

30%

30

35

40

1.112

40%

25

30

35

0.954

50%

30

25

30

0.901

60%

25

25

30

0.848

after 28 days of curing. As the percentage of used foundry

70%

25

20

20

0.689

sand increases the density is reduced. It may be due to the

80%

20

20

20

0.636

increase in the amount of voids in used foundry sand.

90%

25

10

15

0.53

100%

10

15

20

0.477

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1

% Replacement

Chart -4: Dry Density Chart The dry density test was carried out to the mortar cubes

1.5 1 0.5 0 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Split Tensile Strength N/mm2

Split Tensile Strength After 28 Days

% Replacement Chart -3: Tensile Strength chart

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2.6 Sorptivity Test Table -6: Sorptivity Values Wet weight (w2) g 832 820 786 781 780 779 752 743 773 669 668

Sorptivity Value in 10-4 mm/min0.5 0.73 1.09 1.46 1.46 1.83 2.19 2.19 2.56 3.29 4.02 4.39

Sorptivity Value For 1:3 100% 50% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Dry weight (w1) g 830 817 782 777 775 773 746 736 684 657 656

Sorptivity in 10-4 mm/min0.5

% Replace

% Replacement

Sorptivity is the property of materials which characterizes

Chart -5: Sorptivity chart

the tendency of a porous material to absorb and transmit water by capillarity. The prepared cubes were oven dried

2.7 Prism Test

at 850c temperature and initial weight is taken. The cube is

The prism test is approved out to find the compressive

then kept in water with water level not more than 5mm

strength of prism made with the 1:3 mortar mix by using

from the base of cube and the surface flow is prevented by

used foundry sand as substitute for the well aggregate.

sealing with non absorbant coating. The amount of water

The prisms having 5 bricks are casted and cured for 28

absorbed by the cubes in duration of 30 minutes was

days. After 28 days of curative the prisms be experienced

measured and the final weight is taken.

for compressive strength in universal difficult mechanism

Sorptivity can be calculated by using the following

and the readings were recorded to calculate the

formula.

compressive strength of prism.

S=I/

t½

Where,

Table -7: Compressive Strength of Prism after 28 days % Load Compressive REPLACE in kN Strength in N/mm2 0 38.0 1.70 10 36.0 1.61 20 35.0 1.56 30 32.5 1.45 40 28.0 1.25 50 26.5 1.18 60 25.0 1.11 70 24.0 1.07 80 23.0 1.02 90 21.5 0.96 100 18.0 0.80

S= sorptivity in mm, t= elapsed time in minutes, I=Δw/Ad Δw= change in weight = W2-W1 W1 = Oven dry weight of cylinder in grams W2 = Weight of cylinder after 30 minutes capillary suction of water in grams A= surface area of the specimen through which water penetrated d= density of water

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Flexural bond strength for 1:3 mortar mix 0.4

1.5 1 0.5 0

According to the test results following Results are derived. 

The flow value by the replacement of sand with used foundry sand a smaller amount than 40% does not affect the workability of the mortar considerably



The mortar made with used foundry sand absorb more water content reducing the density of mortar. The percentage reduction in density of control mix mortar for 1:3 is 4.32%.



In 1:3 mortar mix, the percentage reduction in strength upto 30% replacement of used foundry sand can be considerable since there is no much difference when compared to control mix, which has compressive strength of 25.73 N/mm2.



At 30% replacement the percentage reduction in compressive strength is 7.7% and after that sudden decrease in strength was observed in such a way that the percentage reduction was about 27.24%.



A reduction in split tensile strength was also be observed in 1:3 mortar mix when compared to control mix at curing age of 28 days whose tensile strength is 1.32 N/mm2.



As in compressive strength here also upto 30% replacement doesn’t affect the strength of 1:3, but later decrease in strength can be noticed in the range of 31.8% reduction in tensile strength of 1:3.



The compression test on prism made with 1:3 mortar mix decreases as the percentage of used foundry sand increases. The compressive strength of masonry prism made with control mix was 1.70 N/mm2.



The flexural bond strength value for 1:3 mortar mix also decreases gradually as the percentage of used foundry sand increases. The flexural bond

2.8 Modified Wrench Test In this study the testing example consists of a heap bond prism of 5 bricks and mortar of 1:3. The flexural bond strength was determined by means of modified bond wrench test put awake. The casted specimens are cured for 28 days and they are tested to find the flexural bond strength.

Table -8: Flexural bund Strength % Replace Flexural bond strength in N/mm2 0 0.389 10 0.387 20 0.358 30 0.336 40 0.242 50 0.236 60 0.236 70 0.230 80 0.208 90 0.207 100 0.203

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% Replacement

3.0 RESULTS AND DISCUSSION

Chart -6: Compressive strength of Prism chart

|

0

Chart -7: Flexural Bond Strength chart

% Replacement

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0.2 0 10 20 30 40 50 60 70 80 90 100

Flexural bond strength in N/mm2

Compressive strength of masonry prism 2

0 10 20 30 40 50 60 70 80 90 100

Compressive Strength in N/mm2

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strength of prism made with 1:3 mortar mix was found to be 0.38 N/mm2.

4.

4.0 CONCLUSIONS The subsequent Conclusions were haggard from this learning 1.

The incorporation of Used Foundry Sand decreases the Compressive Strength of Mortar than control Mortar mix.

2.

By the use of used foundry sand, the cost of construction can be minimized.

3.

Optimum increase in Compressive Strength of mortar was observed with some percentage of UFS, both at 7days, 14 days and 28 Days.

4.

Used Foundry Sand can be conveniently used in making good mortar without compromising the Compressive Strength of Mortar upto 40% of replacement.

5.

Porosity of mortar decrease with increase in used foundry sand.

6.

As there is higher amount of voids present, the density of mortar made with used foundry sand is less than the control mix mortar.

7.

Since the density of mortar is less, the water absorption increase as the percentage of used foundry sand increases.

8.

Sorptivity of the mortar made with used foundry is much higher than the control mortar mix.

9.

The compressive strength and flexural bond strength of prism is valued upto a certain percentage level used foundry sand. That is upto 40% substitute of fine aggregate by second-hand foundry sand can be best suited for the mortar with used foundry sand.

5.

6.

7.

8.

and Technology eISSN: 2319-1163 | pISSN: 23217308 KHURAM RASHID , Prof. Dr. MUHAMMAD AKRAM TAHIR“Evaluation of Concrete Compressive Strength by incorporating Used Foundry Sand” American Journal of Engineering Research (AJER) e-ISSN : 2320-0847 p-ISSN : 2320-0936 Volume03, Issue-02, pp-109-116 GURPREET SINGH, RAFAT SIDDIQUE, “Effect of waste foundry sand as partial replacement of sand on the strength, ultra sonic pulse velocity and permeability of concrete”. Construction and Building Materials published by Science direct, Vol. 26 (2012), pp. 416-422.

DUSHYANT RAMESHBHAI BHIMANI, “Used foundry sand: opportunities for development of eco-friendly low cost concrete”International Journal of Advanced Engineering Technology EISSN 0976-3945IJAET/Vol. IV/ Issue I/Jan.March., 2013/63-66.

VIPUL D. PRAJAPATI1, NILAY JOSHI2, PROF. JAYESHKUMARPITRODA (April-June, 2013) “ used foundry sand: opportunities for developing of low cost rigid pavement” , International Journal of Advanced Engineering Research and Studies EISSN2249–8974 IJAERS/Vol. II/ Issue III/ /69-74.

EKNATH P.SALOKHE1, D.B.DESAI2 “Application of Foundry Waste Sand In Manufacture of Concrete” IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 43-48 www.iosrjournals.org Second International Conference on Emerging Trends in Engineering (SICETE) 43 | Page Dr.J.J.Magdum College of Engineering, Jaysingpur

REFERENCES 1.

2.

3.

TARUN R. NAIK, et al.,(1993) “Utilization of used foundry sand in concrete” PATHARIYA SARASWATI C, RANA JAYKRUSHNA K “Application of waste foundry sand for evolution of low-cost concrete” International Journal of Engineering Trends and Technology (IJETT) – Volume 4 Issue 10 - Oct 2013 | ISSN: 2231-5381 Page 4281.

SMIT M. KACHA, ABHAY et al, “Use of usedfoundry sand (ufs) in concrete” IJRET: International Journal of Research in Engineering

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